Seal arrangement and a method of repairing a seal arrangement

ABSTRACT

The seal arrangement is arranged between the casing portions and a fluoropolymer O-ring seal is positioned between the casing portions. A first protecting member is positioned between the fluoropolymer O-ring seal and the casing portion and the first protecting member consists of a polymer and hydroxyapatite. The first protecting member consists of 50 to 80 wt % polymer and 20 to 50 wt % hydroxyapatite and incidental impurities. The first protecting member is located in an annular groove and is thus arranged between the casing portion and the fluoropolymer O-ring seal. The first protecting member is substantially U-shaped in cross-section and the fluoropolymer O-ring seal is positioned between the legs of the U-shaped cross-section first protecting member. The first protecting member prevents corrosion of the casing portion by the fluoropolymer O-ring seal.

This is a Division of U.S. application Ser. No. 12/757,608 filed Apr. 9,2010, which claims the benefit of Application GB 0907278.6 filed Apr.29, 2009. Each of the disclosures of the prior applications is herebyincorporated by reference herein in its entirety.

The present invention relates to a seal arrangement and a method ofrepairing a seal arrangement and in particular to a seal arrangementbetween components in a gas turbine engine.

It is known to provide a seal between components in a gas turbine engineparticularly an air/oil seal, e.g. an O-ring seal between metal casingsin a gas turbine engine or in an oil/lubrication system of a gas turbineengine. A known type of seal provided between adjacent components in agas turbine engine comprises a fluoropolymer seal. A problem with afluoropolymer seal is that the fluorine, or fluorine-containing species,in the fluoropolymer seal corrodes the adjacent components, after thefluoropolymer seal has degraded at elevated temperatures above 200° C.,and this may lead to surface pitting and sub-surface inter-granularstress-corrosion cracking of the adjacent components. If the componentsare sufficiently corroded it is necessary to repair either one or bothof the adjacent components.

Accordingly the present invention seeks to provide a novel sealarrangement which reduces, preferably overcomes, the above mentionedproblem.

Accordingly the present invention provides a seal arrangement between afirst component and a second component, a fluoropolymer seal member ispositioned between the first component and the second component and afirst protecting member is positioned between the fluoropolymer sealmember and the first component, the first protecting member consistingof a polymer and hydroxyapatite or apatite.

Preferably a second protecting member is positioned between thefluoropolymer seal member and the second component, the secondprotecting member consisting of a polymer and hydroxyapatite or apatite.

The first member may consist of 50 to 80 wt % polymer and 20 to 50 wt %hydroxyapatite and incidental impurities.

The second member may consist of 50 to 80 wt % polymer and 20 to 50 wt %hydroxyapatite and incidental impurities.

Preferably the polymer consists of polyimide.

Preferably the first component has a recess, the first protecting memberis located in the recess between the first component and thefluoropolymer seal member.

Preferably the first protecting member is substantially U-shaped incross-section and the fluoropolymer seal member is positioned betweenthe legs of the U-shaped cross-section first protecting member.

Preferably the second component has a recess, the second protectingmember is located in the recess between the second component and thefluoropolymer seal member.

Preferably the first protecting member is a moulded member.Alternatively the first protecting member is a coating.

Preferably the second protecting member is a moulded member.Alternatively the second protecting member is a coating.

Preferably the first component and the second component comprise ametal. Preferably the metal comprises titanium, a titanium alloy, iron,steel, nickel, a nickel alloy, aluminium, an aluminium alloy or a metalmatrix composite.

Preferably the first component and the second component comprise gasturbine engine components.

Preferably the first component and the second component comprise annularmembers or cylindrical members. Preferably the first component and thesecond component are casings.

The present invention also provides a seal arrangement between a firstcomponent and a second component, a fluoropolymer seal member ispositioned between the first component and the second component and thefluoropolymer seal member consisting of a fluoropolymer andhydroxyapatite or apatitie.

The present invention also provides a method of repairing a sealarrangement between a first component and a second component, afluoropolymer seal member is positioned between the first component andthe second component, the method comprising the steps of:—

(a) disassembling the seal arrangement,

(b) removing the fluoropolymer seal member from between the firstcomponent and the second component,

(c) removing corroded material from the first component, and

(d) positioning a first protecting member between the fluoropolymer sealmember and the first component, the first protecting member consistingof a polymer and hydroxyapatite or apatite.

Preferably step (c) comprises machining the corroded material from thefirst component.

Preferably step (d) comprises positioning a moulded first protectingmember in a recess in the first component. Preferably the firstprotecting member is substantially U-shaped in cross-section.

Alternatively step (d) comprises depositing new material on the firstmember to form a recess and depositing a coating on the surface of therecess to form the first protecting member.

The first member may consist of 50 to 80 wt % polymer and 20 to 50 wt %hydroxyapatite and incidental impurities.

Preferably the polymer consists of polyimide.

Preferably the first component and the second component comprise ametal. Preferably the metal comprises titanium, a titanium alloy, iron,steel, nickel, a nickel alloy, aluminium, an aluminium alloy or a metalmatrix composite.

Preferably the first component and the second component comprise gasturbine engine components.

Preferably the first component and the second component comprise annularmembers or cylindrical members. Preferably the first component and thesecond component are casings.

The present invention will be more fully described by way of examplewith reference to the accompanying drawings in which:—

FIG. 1 shows a turbofan gas turbine engine having a seal arrangementaccording to the present invention.

FIG. 2 shows a casing of the turbofan gas turbine engine having a sealarrangement according to the prior art.

FIG. 3 is an enlarged cross-sectional view through a part of the casingand the seal arrangement according to the prior art shown in FIG. 2.

FIG. 4 shows a casing of the turbofan gas turbine engine having a sealarrangement according to the present invention.

FIG. 5 is an enlarged cross-sectional view through a part of the casingand the seal arrangement according to the present invention shown inFIG. 4.

FIG. 6 is an enlarged cross-sectional view through a part of the casingand an alternative seal arrangement according to the present inventionshown in FIG. 4.

FIG. 7 is an enlarged cross-sectional view through a part of the casingand a further seal arrangement according to the present invention shownin FIG. 4.

A turbofan gas turbine engine 10, as shown in FIG. 1, comprises in axialflow series an inlet 12, a fan section 14, a compressor section 16, acombustion section 18, a turbine section 20 and an exhaust 22. The fansection 14 comprises a fan 24 and the compressor section 16 comprises anintermediate pressure compressor 26 and a high pressure compressor 28.The turbine section 20 comprises a high pressure turbine 30, anintermediate pressure turbine 32 and a low pressure turbine 34. The lowpressure turbine 34 is arranged to drive the fan 24 via a first shaft36, the intermediate pressure turbine 32 is arranged to drive theintermediate pressure compressor 26 via a second shaft 38 and the highpressure turbine 30 is arranged to drive the high pressure compressor 28via a third shaft 40. FIG. 1 also shows a compressor casing 48 for theintermediate and high pressure compressors 26 and 28 respectively. Theturbofan gas turbine engine 10 operates quite conventionally and itsoperation will not be discussed further.

The compressor casing 48 comprises two axially adjacent casing portions50 and 52 and a prior art seal arrangement 54 is provided between thecasing portions 50 and 52 as shown more clearly in FIGS. 2 and 3. Theadjacent axial ends 56, 58 of the casing portions 50 and 52 respectivelyhave radially extending flanges 60, 62 and the flanges 60, 62 arefastened together by a plurality of bolts 64 and nuts 66. An end surface68 of the casing 50 and flange 60 is provided with a circumferentiallyextending annular recess, or annular groove, 70 and an O-ring seal 72 isprovided in the annular groove 72 to provide a seal between the surfaces68 and 69 on the flanges 60, 62 of the axially adjacent casing portions50 and 52. The O-ring seal 72 consists of a fluoropolymer, i.e. apolymer containing fluorine. As mentioned previously, fluorinecontaining species liberated from the fluoropolymer O-ring seal 72corrode the adjacent surfaces of the casing portions 50 and 52 once thefluoropolymer O-ring seal 72 has been degraded at temperatures above200° C.

A seal arrangement 154 according to the present invention is shown inFIGS. 4 and 5. The seal arrangement 154 is generally the same as thatshown in FIGS. 2 and 3, and like parts are denoted by like numerals. Theseal arrangement 154 is arranged between the casing portions 50 and 52and a fluoropolymer O-ring seal 72 is positioned between the casingportions 50 and 52. The present invention provides a first protectingmember 156 positioned between the fluoropolymer O-ring seal 72 and thecasing portion 50 and the first protecting member 156 consists of apolymer and hydroxyapatite. The first protecting member consists of 50to 90 wt % polymer and 10 to 50 wt % hydroxyapatite and incidentalimpurities, more preferably 50 to 80 wt % polymer and 20 to 50 wt %hydroxyapatite and incidental impurities, and the hydroxyapatite powderhas a particle size of about 100 micrometers. The first protectingmember 156 is located in the annular groove 70 and is thus arrangedbetween the casing portion 50 and the fluoropolymer O-ring seal 72. Thefirst protecting member 156 is substantially U-shaped in cross-sectionand the fluoropolymer O-ring seal 72 is positioned between the legs157A, 157B of the U-shaped cross-section first protecting member 156.

A second protecting member 158 is positioned between the fluoropolymerO-ring seal 72 and the casing portion 52 and the second protectingmember 158 consists of a polymer and hydroxyapatite. The second member158 also consists of 50 to 90 wt % polymer and 10 to 50 wt %hydroxyapatite and incidental impurities, more preferably 50 to 80 wt %polymer and 20 to 50 wt % hydroxyapatite and incidental impurities, andthe hydroxyapatite powder has a particle size of about 100 micrometers.The casing portion 52 is also provided with a circumferentiallyextending annular recess, or annular groove, 160 in the surface 69 onthe end of the flange 62 and casing portion 52. The second protectingmember 158 is located in the annular groove 160 and is thus between thecasing portion 52 and the fluoropolymer O-ring seal 72.

The polymer in the protecting members 156 and 158 consists of polyimide,although other suitable polymers may be used depending on thetemperature requirements of the protecting members 156 and 158. In thisembodiment of the present invention the first protecting member 156 is amoulded member and the second protecting member 158 is a moulded member.Polyimide precursor monomers and anhydrous hydroxyapatite powder ofparticle size around 100 micrometers are mixed together and theninjected into a mould in the shape of the first protecting member. Themixture is cured at an appropriate temperature and time, for example itis cured at a temperature of 320° C. at a mould pressure of 200 poundsper square inch, 1379 kPa. The finished first protecting member isremoved from the mould and optionally may be post-cure heat treated at360° C. at atmospheric pressure in air to increase temperaturecapability.

The casing portions may comprise a metal, for example the metalcomprises titanium, a titanium alloy, iron, steel, nickel, a nickelalloy, aluminium, an aluminium alloy or a metal matrix composite e.g. atitanium alloy consisting of 6 wt % aluminium, 4 wt % vanadium and thebalance titanium, minor additions and incidental impurities.

The first protecting member 156 may be used to repair a used sealarrangement 54 which has suffered from corrosion. The seal arrangement54 is firstly dis-assembled, and then the fluoropolymer O-ring sealmember 72 is removed from between the casing portions 50 and 52.Corroded material is removed from the casing portion 50 and then a firstprotecting member 156 is positioned between the fluoropolymer O-ringseal 72 and the casing portion 50, the first protecting member 156consists of a polymer and hydroxyapatite. The corroded material isremoved from the casing portion 50 by machining or other suitabletechnique. The first protecting member 156 is a pre-moulded componentand is positioned in the annular groove 70 in the casing portion 50.Preferably the first protecting member 156 is substantially U-shaped incross-section as mentioned above. Thus the present invention increasesthe depth of an existing annular groove 70 in the casing portion 50 andthen provides the first protecting member 156 to redefine the annulargroove for the fluoropolymer O-ring seal 72. A fluoropolymer O-ring seal72 is then repositioned between the casing portions 50 and 52 with thefirst protecting member 156 positioned between the fluoropolymer O-ringseal 72 and the casing portion 50,

Similarly corroded material may be removed from the casing portion 52 todefine an annular groove 160 and then a second protective member 158B isprovided in the annular groove 160 between the casing portion 52 and thefluoropolymer O-ring seal 72.

Although two protecting members have been described it may be possibleto provide only one of the protecting members.

An alternative seal arrangement 154B according to the present inventionis shown in FIGS. 4 and 6. The seal arrangement 154B is generally thesame as that shown in FIGS. 4 and 5, and like parts are denoted by likenumerals. This seal arrangement 154B differs in that the firstprotecting member 156B is a coating and the second protecting member158B is a coating.

The first protecting member 156B may be used to repair a used sealarrangement 54 which has suffered from corrosion. The seal arrangement54 is firstly dis-assembled, and then the fluoropolymer O-ring sealmember 72 is removed from between the casing portions 50 and 52.Corroded material is removed from the casing portion 50. New material162B is deposited on the casing portion 50 to reform the annular groove70 and then a coating is deposited on the surface of the new material162B defining the annular groove 70 to form the first protecting member156B. A fluoropolymer O-ring seal 72 is then repositioned between thecasing portions 50 and 52 with the first protecting member 156Bpositioned between the fluoropolymer O-ring seal 72 and the casingportion 50, the first protecting member 156 consists of a polymer andhydroxyapatite. The corroded material is removed from the casing portion50 by machining or other suitable technique. Preferably the firstprotecting member 156B is substantially U-shaped in cross-section. Thusthe present invention increases the depth of an existing annular groove70 in the casing portion 50 and then reforms the annular groove 70 withnew material 162B to redefine the annular groove 70 for thefluoropolymer O-ring seal 72 and provides a thin coating of firstprotecting member 156B in the annular groove 70.

Similarly corroded material may be removed from the casing portion 52 todefine an annular groove 160 and then new material 164B is deposited tosubstantially fill the annular groove 160 and then a thin coating ofsecond protective member 158B is provided onto the new material 164B.The first and second protective members 156B and 158B consist of 75 to90 wt % polymer and 10 to 25 wt % hydroxyapatite and incidentalimpurities

The new material 162B and 164B may be deposited by any suitable method,for example plasma spraying, direct laser deposition, weld metaldeposition etc and the new material is preferably the same as thematerial of the casing portion 50 or 52, but may be different.

In a further embodiment of the present invention, the seal arrangementis substantially the same as that shown in FIGS. 2 and 3, and like partsare denoted by like numerals. In FIG. 7 the fluoropolymer O-ring seal254 is positioned between the casing portions 50 and 52 thefluoropolymer O-ring seal 254 is positioned between the casing portion50 and the casing portion 52 and the fluoropolymer O-ring seal 254consists of a fluoropolymer and hydroxyapatite. The fluoropolymer O-ringseal 254 is positioned in the annular groove 70 in the surface 68 at theaxial end of the casing portion 50 and flange 60.

The seal arrangement may be an air/gas seal or a liquid seal, e.g.lubricant/oil seal, or an air/oil seal or a fuel seal or a hydraulicfuel seal.

The hydroxyapatite powder in the first protecting member and/or secondprotecting member and/or fluoropolymer O-ring seal scavenges freefluoride ions and/or volatile fluorine containing species, e.g. hydrogenfluoride, from the surrounding environment. This occurs even though thehydroxyapatite is encased in the polymer, polyimide, matrix becausefluoride ions are exceptionally small and mobile and they rapidlydiffuse through close-packed atomic structures, while the polymer,polyimide, matrix has a relatively open structure with only limitedlong-range order. The hydroxyapatite may be used to protect metalcomponents and other components from the corrosive action of fluorinecontaining seal members.

Although the present invention has been described with reference to afluoropolymer O-ring seal between two casing portions it is equallypossible to provide a fluoropolymer O-ring seal between two annularmembers or between two cylindrical members. It may also be possible toprovide a fluoropolymer seal between a first component and a secondcomponent. The present invention is also applicable to other types ofseals for example gasket seals, D-ring seals, spring-energised seals orother seals consisting of a fluoropolymer.

Although the present invention has been described with reference to gasturbine engine components it is equally suitable for use for seals withinternal combustion engine components, e.g. diesel engine components,and other components.

The amount of hydroxyapatite added to the polymer of the firstprotective member, second protective member or fluoropolymer seal memberis varied depending on the degree of severity of the corrosiveenvironment, which tends to increase the amount of hydroxyapatite added,and the degree of mechanical strength required, which tends to decreasethe amount of hydroxyapatite added.

Although the present invention has been described with reference to theuse of hydroxyapatite it may also be possible to use apatite in place ofhydroxyapatite.

The invention claimed is:
 1. A method of repairing a seal arrangementbetween a first component and a second component, a fluoropolymer sealmember is positioned between the first component and the secondcomponent, the method comprising the steps of:— (a) disassembling theseal arrangement, (b) removing the fluoropolymer seal member frombetween the first component and the second component, (c) removingcorroded material from the first component, and (d) positioning a firstprotecting member between the fluoropolymer seal member and the firstcomponent, the first protecting member consisting of a polymer andhydroxyapatite or apatite, wherein the first component comprises a metalwherein the first component has a first recess and the fluoropolymerseal is positioned in the recess, step (c) comprises increasing a depthof the first recess in the first component and step (d) comprisespositioning the first protecting member in the first recess such thatthe first protecting member is between the fluoropolymer seal member andthe first component.
 2. A method as claimed in claim 1 wherein step (c)comprises machining the corroded material from the first component.
 3. Amethod as claimed in claim 1 wherein in step (d), the first protectingmember is a molded member.
 4. A method as claimed in claim 1 wherein thefirst protecting member is substantially U-shaped in cross-section.
 5. Amethod as claimed in claim 1 wherein the first protecting memberconsists of 50 to 80 wt % polymer and 20 to 50 wt % hydroxyapatite andincidental impurities.
 6. A method as claimed in claim 1 wherein thepolymer consists of polyimide.
 7. A method as claimed in claim 1 whereinthe fluoropolymer seal is positioned in the first recess, step (c)comprises increasing a depth of the first recess in the first componentand step (d) comprises depositing new material within the first recessin the first component to form a recess having a surface, and depositinga coating on the surface of the recess to form the first protectingmember such that the first protecting member is between thefluoropolymer seal member and the first component.
 8. A method asclaimed in claim 1 wherein the first component and the second componentcomprise gas turbine engine components.
 9. A method as claimed in claim1 wherein the first component and the second component comprise annularmembers.
 10. A method as claimed in claim 1 wherein the metal isselected from the group consisting of titanium, a titanium alloy, iron,steel, nickel, a nickel alloy, aluminum, an aluminum alloy and a metalmatrix composite.
 11. A method of repairing a seal arrangement between afirst metal component and a second metal component, a fluoropolymer sealmember being positioned between the first metal component and the secondmetal component, the method comprising the steps of: (a) disassemblingthe seal arrangement, (b) removing the fluoropolymer seal member frombetween the first metal component and the second metal component, (c)removing corroded material from the first component, (d) positioning afirst protecting member between the fluoropolymer seal member and thefirst metal component, the first protecting member consisting of apolymer and hydroxyapatite or apatite, (e) removing corroded materialfrom the second component, and (f) positioning a second protectingmember between the fluoropolymer seal member and the second metalcomponent, the second protecting member consisting of a polymer andhydroxyapatite or apatite wherein the first metal component has a firstrecess and the fluoropolymer seal is positioned in the recess, step (c)comprises increasing a depth of the first recess in the first metalcomponent and step (d) comprises positioning the first protecting memberin the first recess such that the first protecting member is between thefluoropolymer seal member and the first metal component.
 12. A method asclaimed in claim 11 wherein step (e) comprises forming a second recessin the second component and step (f) comprises positioning the secondprotecting member in the second recess such that the second protectingmember is between the fluoropolymer seal member and the secondcomponent.
 13. A method as claimed in claim 12 wherein step (f)comprises depositing new material within the second recess in the secondcomponent to substantially fill the second recess, and depositing acoating on the new material to form the second protecting member suchthat the second protecting member is between the fluoropolymer sealmember and the second component.
 14. A method as claimed in claim 11wherein the metal is selected from the group consisting of titanium, atitanium alloy, iron, steel, nickel, a nickel alloy, aluminum, analuminum alloy and a metal matrix composite.
 15. A method as claimed inclaim 11 wherein the first protecting member is substantially U-shapedin cross-section and comprises two spaced legs, step (d) comprisespositioning the first protecting member in the first recess andpositioning the fluoropolymer seal member between the legs of theU-shaped cross-section first protecting member.